Clutch: Service and Repair

PRESSURE PLATE
Removal/Inspection

1. Assemble the special tools with the "A" side of the Clutch Alignment Disc facing the diaphragm spring.





2. Check the diaphragm spring fingers for height using the special tools and a feeler gauge.

If the height is more than the service limit, replace the pressure plate.





3. Install the special tools as shown.
4. To prevent warping, unscrew the pressure plate mounting bolts in a crisscross pattern in several steps, then remove the pressure plate.
5. Inspect the pressure plate surface for wear, cracks, and burning.





6. Inspect the fingers of the diaphragm spring for wear at the release bearing contact area.





7. Inspect for warpage using a straight edge and feeler gauge. Measure across the pressure plate.

If the warpage is more than the service limit, replace the pressure plate.

CLUTCH DISC
Removal/Inspection
1. Remove the clutch disc and special tools.





2. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it.





3. Measure the clutch disc thickness.

If the thickness is less than the service limit, replace the clutch disc.





4. Measure the rivet depth from the lining surface to the rivets, on both sides.

Standard (Now): 1.65 - 2.25 mm (0.06 - 0.09 inch)
Service Limit: 0.2 mm (0.008 inch)

If the rivet depth is less than the service limit, replace the clutch disc.

INSTALLATION





1. Install the ring gear holder.
2. Apply grease to the splines of the clutch disc, then install the clutch disc using the special tools as shown.

NOTE: Use only Super High Temp Urea Grease (P/N 08798-9002).





3. Install the pressure plate and the mounting bolts finger-tight.





4. Torque the mounting bolts in a crisscross pattern as shown. Tighten the bolts in several steps to prevent warping the diaphragm spring.

5. Remove the special tools.

6. Check the diaphragm spring fingers for height.